Flexible sturdy base container and method for making the same

ABSTRACT

Flexible sturdy base containers and methods for manufacturing the same are provided. The flexible sturdy base container includes a rigid base element formed of a relatively rigid material. The rigid base element includes a bottom and a perimeter wall having an outward facing surface. The container also includes a flexible wall element formed of a relatively flexible material. The flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. The flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.

FIELD

The present disclose relates generally to flexible containers, and more particularly to a flexible container with a rigid base.

BACKGROUND

Containers for foodstuffs and other bulk materials are made from various rigid or flexible materials in various configurations. Despite the availability of many different known flexible and rigid packaging designs, there remains a need for new containers for foodstuffs and other bulk materials that can be manufactured cost effectively and that can provide advantageous properties.

SUMMARY

In one aspect, a flexible sturdy base container is provided. The flexible sturdy base container includes a rigid base element comprising a relatively rigid material. The rigid base element includes a bottom and a perimeter wall having an outward facing surface. The container also includes a flexible wall element comprising a relatively flexible material. The flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. The flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.

In another aspect, a method of manufacturing a flexible sturdy base container is provided. The method includes transporting a rigid base element comprising a relatively rigid material to a flexible wall element application station. The rigid base element has a bottom and a perimeter wall having an outward facing surface. The method also includes applying a flexible wall element around the perimeter wall of the rigid base element at the flexible wall element application station without covering the bottom of the rigid base element. The flexible wall element comprises a relatively flexible material. The method also includes affixing the flexible wall element to the perimeter wall of the rigid base element to produce the flexible sturdy base container.

DRAWINGS

FIG. 1 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIG. 2 is a side view, illustrating one of the flexible sturdy base containers of FIG. 1.

FIG. 3 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIG. 4 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIGS. 5A-C are perspective views, illustrating use of one of the flexible sturdy base containers of FIG. 4.

FIG. 6 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIGS. 7A-C are perspective views, illustrating use of one of the flexible sturdy base containers of FIG. 6.

FIG. 8 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIG. 9 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIG. 10 is a perspective view, illustrating two flexible sturdy base containers made in accordance with one or more embodiments of the present invention.

FIG. 11 is a perspective view, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.

FIGS. 12A-C are perspective views, illustrating use of the flexible sturdy base container of FIG. 11.

FIG. 13 is a perspective view, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.

FIGS. 14A and 14B are perspective views, illustrating use of the flexible sturdy base container of FIG. 13.

FIG. 15 is a side view, illustrating a method of manufacturing a sturdy base container in accordance with one or more embodiments of the present invention.

FIGS. 16A and 16B are orthogonal views, illustrating a method of manufacturing a sturdy base container in accordance with one or more embodiments of the present invention.

FIG. 17 is a side view, illustrating a method of filling and sealing a sturdy base container in accordance with one or more embodiments of the present invention.

FIG. 18 is a perspective view, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.

FIGS. 19A, 19B, and 19C are perspective views, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.

FIGS. 20A and 20B, are a side view and a bottom view, respectively, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.

FIGS. 21A and 21B, are a side view and a bottom view, respectively, illustrating a flexible sturdy base container made in accordance with one or more embodiments of the present invention.

FIGS. 21C and 21D, are perspective views, illustrating the flexible sturdy base container of FIGS. 21A and 21B.

DETAILED DESCRIPTION

New containers are disclosed that provide various advantages over presently-available container designs. Methods are also provided for manufacturing such containers. In one aspect, a flexible sturdy base container is provided that includes a rigid base element made from a relatively rigid material and a flexible wall element made from a relatively flexible material. As used herein the terms “relatively rigid material” and “relatively flexible material” are intended to denote that one material, i.e., the relatively rigid material, is more rigid than the other material, i.e., the relatively flexible material. The relatively rigid material may be any material suitable for providing structural integrity to the base of the container. For example, the material may be sufficiently rigid to allow the container to stand up vertically when placed on its base. In some embodiments, the material may be sufficiently rigid to prevent the container from tipping over when placed on its side.

In some embodiments, the base is made of a rigid or semi-rigid material and the side wall is made of a flexible material. The term “rigid material,” as used herein, is used in the ordinary sense and refers to materials that are characterized by a degree of stiffness that would be considered rigid in the packaging and converting industry. Often these materials are made by blow molding, injection molding, or thermoforming processes. For example, the rigid base element may be made by thermoforming an extruded sheet. The term “flexible material,” as used herein, is used in the ordinary sense and refers to materials that are characterized by a degree of flexibility (e.g., to bending) that would be considered flexible in the packaging and converting industry. Often these materials are relatively thin webs or films produced by extrusion processes. The term “semi-rigid material,” as used herein, is used in the ordinary sense and refers to materials that are characterized by a degree of stiffness that would be considered semi-rigid in the packaging and converting industry. These materials may also be considered rigid or flexible. The terms “rigid” “semi-rigid” and “flexible” are extensive qualities that depend not only on the specific composition of the material but also the material's thickness, structure, and method of forming.

The rigid base element may allow the container to stand vertically on its base or may allow the container to lay on its side without tipping over. Such a feature may be advantageous in retail settings where visible shelf space is limited. The rigid base may also provide protection for fragile dry products, e.g., it may reduce or prevent breaking of flakes. The rigid base may also allow for the container to stand up when it is partially filled. Thus, the container may be pantry, counter and table-top friendly. The rigid base may customized depending on the nature of the product and the needs of the customer and/or retailer. For example, the base can be formed in a shape consistent with ergonomic needs (e.g., it can be shaped to be easier to hold in the consumer's hand) or the base can be shaped such that the product stores better on a retailer shelf or is better for packing and/or shipping.

The flexible wall element may occupy the majority of the exterior surface area of the package and/or a majority of the packaging material by mass, thereby making efficient use of the materials. The flexible wall element may also be made from thin films, thereby allowing for customizable barrier properties. Likewise, the rigid base may be thermoformed or co-injection molded for oxygen barrier properties if necessary. Such features may allow for customization of the barrier properties for different types of products (e.g., dry, frozen, fresh, oxygen sensitive, moisture sensitive, or respiring). The flexible wall material may be customizable in shape, providing excellent customization and product differentiation opportunities. The flexible wall element may also allow for various convenience features (such as easy-open or reclosable features) to be viewed. The flexible wall element may also include a product viewing window.

The container, having a sturdy base and a flexible top, may also allow for open-top filling. Advantageously, in some embodiments, the container may be employed in high-speed filling and sealing systems. Moreover, the container may be made predominantly from a single polymer. For example, the container may be made predominantly of polypropylene, which is lightweight, cost effective, and recyclable. In some embodiments, the container may be made predominantly of polylactic acid, which is renewable and compostable.

The container may be used to contain various food and other bulk products, such as granular products or products that can be gravity-fed. The bulk product can also include smaller packages, such as candy or individual servings of product. In some embodiments, the container may contain breakfast cereals, salty snacks, pasta, crackers, popcorn, nuts, dried fruits, confectionaries, chocolate, and other baked or fried goods and/or dry products. In some embodiments, the container may contain frozen food products, including frozen meat, seafood, vegetables, fruit, and combinations thereof. In other embodiments, the container may contain non-food items including laundry and dish-washing detergents, fertilizers, insecticides, pesticides and other granulated products.

Flexible Sturdy Base Container

In one aspect, a flexible sturdy base container is provided that includes a rigid base element made from a relatively rigid material and a flexible wall element made from a relatively flexible material. In some embodiments, the rigid base element includes a bottom and a perimeter wall having an outward facing surface. In some embodiments, the flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element. In some embodiments, the flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.

An exemplary embodiment of a flexible sturdy base container 10 is illustrated in FIG. 1. The illustrated flexible sturdy base container 10 includes a rigid base 18 that forms the bottom 14 of the container 10. A flexible side wall 16 is affixed to a rigid base 18. The flexible side wall 16 may extend from proximal to the bottom 14 of the container 10 to the top 12 of the container 10. At the top 12 of the container 10 an end seal 20 may be provided. The end seal may be, for example, a heat seal. In the illustrated embodiment, the end seal 20 comprises a heat seal region that extends across the entirety of the top 12 of the container 10 thereby sealing the end of the flexible side wall 16 opposite the rigid base 18.

The bottom 14 may include a reclosable lid 22. The reclosable lid 22 may pivot with respect to the bottom 14 by a hinge 24, which may be a living hinge. As illustrated in FIG. 2, the reclosable lid 22 may be selectively positionable in an open position and a closed position (FIG. 1). When the reclosable lid 22 is positioned in the open position, a spout opening 30 is uncovered, thereby allowing access to the contents of the container 10. Various locking features may be provided for retaining the reclosable lid 22 in the closed position. For example, the spout opening 30 may include an external rib 28. The reclosable lid 22 may also include an internal rib 26 that mechanically engages the external rib 28 when the reclosable lid 22 is moved to the closed position. Engagement of the internal rib 26 and external rib 28 may prevent the reclosable lid 22 from opening inadvertently, such as when moving the container from one location to another.

As illustrated in FIG. 2, the flexible side wall 16 may be affixed to the rigid base 18 along a perimeter wall 25 of the rigid base 18. The flexible side wall 16 may be affixed to the perimeter wall 25, for example, by thermal, ultrasonic, RF or adhesive bonding. In the illustrated embodiment, the flexible side wall 16 terminates proximal the bottom of the rigid base 14; however, an exposed portion 27 of the perimeter wall 25 is left uncovered by the flexible side wall 16.

In preferred embodiments, the flexible side wall material may be affixed to itself by a lap seam type seal that extends from the end of the flexible side wall proximal to the rigid base to the opposite end of the flexible side wall at the top of the container. The lap seam may be formed by sealing together, at respective edges, an outward-facing surface of the flexible side wall and an inward-facing surface of the flexible side wall. The seal may be created by thermal bonding, RF bonding, ultrasonic bonding, adhesive bonding, or a combination thereof. The lap seam not only provides an efficient use of material for flexible sturdy base container configurations but also provides improved structural strength and improved sealing relative to fin seals or butt seams. Specifically, it is noted that the lap seam induces an outward-exerting spring force within the flexible wall that provides natural resistance to folding. The lap seam also allows for the flexible material to be wrapped around the outward facing surface of the perimeter wall of the rigid base. This allows for a better seal to be formed between the flexible side wall and reduces or eliminates channels and wrinkling, which could compromise the sealing of the contents of the package.

Another embodiment of a flexible sturdy base container 32 is illustrated in FIG. 3. The container 32 includes a rigid base 36 at the bottom 38 of the container 10 and a flexible side wall 34 extending from proximal to the bottom 38 of the container 10 to the top 40 of the container 10. The rigid base 36 may include a recessed panel 42 that is separated from bottom 38 by a standoff 44. The rigid base 36 may also include a reclosable lid 46 that is attached to the recessed panel 42 by a hinge 48, which may be a living hinge. The reclosable lid 46 may include a tab 50 that is elevated from the recessed panel 42 to facilitate opening.

Another embodiment of a flexible sturdy base container 52 is illustrated in FIG. 4. The container includes a rigid base having an annular shaped bottom 56. A recessed panel 54 is separated from bottom 56 by a standoff 60. As illustrated in FIG. 5A, the reclosable lid 62 may be manipulated to the open position to reveal a removable seal 64. The removable seal 64 may be a tamper-evident membrane that is configured to indicate to the user whether the container had previously been opened. The removable seal could be a lidding membrane that provides barrier properties as well as tamper evidency. Other tamper-evident features, including heat-shrunk bands placed over the lid, may be employed in addition to or in place of the removable seal 64.

Referring back to FIG. 5A, the removable seal 64 may then be peeled or torn away to reveal an opening 66, providing access to the contents of the container 52. With the reclosable lid 62 in the open position, the contents of the container 52 may be poured out into a hand or a container 65 as illustrated in FIG. 5B. As illustrated in FIG. 5C, the container 52 may be easily reclosed by pivoting the reclosable lid 62 about the hinge 58 until reclosable lid 62 snaps back into the closed position.

Another embodiment of a flexible sturdy base container 70 is illustrated in FIG. 6. The container 70 includes a flexible side wall 72 and a rigid base 74. A reclosable lid 78 is attached to the bottom 76 of the ridge base 74 by a hinge 80, which may be a living hinge. For additional security, the rigid base 74 further includes locking 78 which securely engages the reclosable lid 78 and maintains the reclosable lid 78 in the closed position until the locking tab 80 is pulled away from the reclosable lid 78. A recess 82 is provided in the reclosable lid 82 to provide a space for inserting the end of a finger to pull away the locking tab 80 from the reclosable lid as illustrated in FIG. 7A. With the reclosable lid 82 in the open position, the contents of the container 70 may be poured out into a hand or a container 84 as illustrated in FIG. 7B. As illustrated in FIG. 7C, the container 70 may be reclosed by pivoting the reclosable lid 78 back to the closed position and pressing the locking tab 80 back into position to secure the reclosable lid 78.

Another embodiment of a flexible sturdy base container 86 is illustrated in FIG. 8. The container 86 includes a flexible side wall 88 that is affixed to a rigid base 90. The rigid base may include a recessed panel 96 that is separated from the bottom 92 of the rigid base 90 by a standoff 95. The rigid base also includes a reclosable lid 98 that is attached to the recessed panel 96, for example, by a hinge. The embodiment illustrated in FIG. 8, like the embodiments of FIGS. 1 and 6, has a rigid base 90 having a perimeter wall with flat, substantially planar portions on opposite sides of the rigid base 90. These flat, substantially planar portions may allow the container 86 to lay flat on its side with stability, i.e., without tipping over.

Another embodiment of a flexible sturdy base container 100 is illustrated in FIG. 9. The container 100 includes a rigid base 108 and a flexible side wall 106 extending from proximal to the bottom 104 of the container 100 to the top 102 of the container 100. The rigid base 108 includes a reclosable lid 110 that is attached to the rigid base 108 by a hinge. The rigid base 108 also includes a perimeter wall having two pairs of opposing flat, substantially planar portions 114 and 116. In this embodiment, the container 100 may rest stably on the rigid base 104 in the vertical orientation or may rest stably on any of its sides.

Another embodiment of a flexible sturdy base container 120 is illustrated in FIG. 10. The container 120 includes a rigid base 129 and a flexible side wall 126 extending from proximal to the bottom 130 of the container 120 to the top 122. The top 122 of the container 120 may be heat sealed, and a handle 124 may be formed by a cutout within the heat seal region. The handle 124 may be reinforced by the addition of a reinforcing layer. A reclosable lid 132 is provided in the rigid base 128 at the bottom 130.

Another embodiment of a flexible sturdy base container 140 is illustrated in FIG. 11. The container 140 includes a rigid base 152 and a flexible side wall 150 extending from proximal to the bottom 154 of the container 140 to the top 146. A heat seal region 148 may also be provided along the top 146, and a stress riser 144 may be provided in the flexible side wall 150, for example, in the heat seal region 148. The stress riser 144 may be configured to propagate a tear 145 when the user grasps a tear-away portion 142 and pulls as illustrated in FIG. 12A. When the tear-away portion 142 is torn from the container 140, an opening 146 is formed as illustrated in FIG. 12B. The opening 146 may be used as a spout to pour the contents of the container 140 into a hand or a container 152. The container 140 then may be reclosed by folding a folded portion 150 over the opening 146 and placing a clip 148 over the fold as illustrated in FIG. 12C.

Another embodiment of a flexible sturdy base container 160 is illustrated in FIG. 13. The container 160 includes a rigid base 172 and a flexible side wall 166. The flexible side wall 166 has a heat-seal region 170 at the top 168. The top 168 may also include a tear-away portion 162 which, when removed, reveals an internal locking feature 164. As illustrated in FIG. 14A, the container 160 may be opened by tearing away tear-away portion 162 to produce an opening 174 providing access to the contents of the container 160. As illustrated in FIG. 14B, the container 160 may then be closed by compressing the internal locking feature 164. The internal locking feature 164 may be, for example, interlocking ribs, tabs, a zipper, hook and loop fasteners, or pressure sensitive adhesive.

The embodiments illustrated in FIGS. 1-14 are intended to be illustrative of the various features and configurations possible for flexible sturdy base containers according to one or more embodiments of the present invention. It should be appreciated that the various features that are illustrated in one embodiment (including shapes of the rigid base, the presence or absence of a recessed panel, handle, reclosable feature, locking tab, stress riser or tear-way portion) may be incorporated and used in each of the other illustrated embodiments. For example, as illustrated in FIG. 18, a flexible sturdy base container 500 may include a top 54, an internal reclose feature 502 proximal the top 504, and a flat rectangular shaped base 506. In another example, as illustrated in FIGS. 19A-C, a flexible sturdy base container 600 may include a handle 604, a tear away portion 602, and an internal locking feature 606 all located in a top portion of the container 600. In yet another example, as illustrated in FIGS. 20A and 20B, a flexible sturdy base container 700 can include a substantially triangular-shaped bottom 702 having a reclosable lid 704 integrated to the bottom 702 by a hinge 706. In yet another example, a flexible sturdy base container 800 may have a substantially triangular-shaped bottom 802 and a gusset 804 on one side with an internal locking feature 806 within a folded portion of the gusset. The gusset 804 may be opened (i.e., unfolded) to create an opening or pour spout for providing access to the contents of the container 800.

Flexible Wall Element

The flexible wall element may be made of a relatively flexible material, which may be a flexible material. In some embodiments, the relatively flexible material is sufficiently flexible to allow the top of the container to be rolled or folded over. In some embodiments, the relatively flexible material comprises a polymeric material. For example, the relatively flexible material may comprise a relatively thin polymeric film or web.

In certain embodiments, the relatively flexible material may be a multilayer laminate structure. In an exemplary embodiment, the multilayer laminate structure may include one or more of a heat-sealable inner layer, an oxygen and/or a vapor barrier layer, and a print layer. Other layers serving other functions may also be employed.

The heat-sealable inner layer may comprise any heat-sealable material. Exemplary heat-sealable materials include, but are not limited to, thermoplastic polymeric materials, such as polypropylene, polyethylene, polylactic acid, copolymers of polypropylene, copolymers of polyethylene, heat sealable PET, PET copolymers, and biodegradable and compostable thermoplastics.

The oxygen and/or vapor barrier layer may comprises any material suitable for provided the desired oxygen and/or vapor barrier performance qualities. In some embodiments, the multilayer laminate structure provides a gas permeability of less than 100 cc/100 in²/24 hrs, or more preferably less than 10 cc/100 in²/24 hrs, or most preferably less than 0.1 cc/100 in²/24 hrs. Exemplary barrier layer materials include metal films (e.g., aluminum films), metalized polyolefin films, and copolymers of vinyl alcohol (EVOH, PVOH), metalized PLA, aluminum oxide coated PET, silicon oxide coated PET, nylon, metalized nylon, and polyglycolic acid (PGA) films.

In some embodiments, the flexible wall element extends from approximately the bottom of the container to the top of the container. In certain embodiments, a portion of the rigid base is exposed between the top and the bottom of the container. In such embodiments, the flexible wall element, an exposed portion of the perimeter wall of the rigid base element, and the bottom of the rigid base element together form an exterior of the flexible sturdy base container. In other embodiments, the flexible wall element may extend from the top of the container to the bottom of the container without covering the bottom. In such embodiments, no portion of the perimeter wall of the rigid base may form the exterior of the container, i.e., the entirety of the perimeter wall may be covered by the flexible wall element.

In some embodiments, the top of the flexible wall includes a heat seal region in which opposite sides of the flexible wall are heat-sealed together. Alternatively, in some embodiments, the heat seal region may be a bonding region in which the opposite sides of the flexible wall are bonded by ultrasonic bonding or RF bonding. In some embodiments, the heat seal or bonding region may extend across the entirety of the top of the container, thereby hermetically sealing the container and its contents. In some embodiments, the container may include a stress riser placed in the heat seal or bonding region that is designed to propagate a tear when a tear away portion is pulled by a user to provide access to the contents of the container.

In some embodiments, the container may include a reclosable element integrated or attached to the flexible wall element. The reclosable element may allow for the selective closure of an end of the flexible wall element. Various reclosable elements may be employed including, but not limited to, interlocking ribs, tabs, zippers, hook and loop fasteners, or pressure sensitive adhesive.

Rigid Base Element

The rigid base element may be made of a relatively rigid material, which may be a rigid material. In some embodiments, the rigid base element may be a molded or thermoformed article. For example, the relatively rigid material may be formed of a plastic material. Exemplary materials for forming the rigid base include polypropylene, polyethylene, polyethylene teraphthalate, copolymers of polypropylene, copolymers of polyethylene, EVOH, styrene, ABS, PVC, PVDC, copolymers of styrene, multilayer materials, composite materials, and bioderived materials.

The rigid base element may include a bottom and a perimeter wall having an outward facing surface for mating with and bonding with the flexible wall element. The outward-facing surface may include ribs, etching, or other surface characteristics to improve manufacturing or the consumer experience. In some embodiments, the bottom of the rigid base may comprise a flat, substantially planar surface covering the area circumscribed by the perimeter wall. In other embodiments, the bottom of the rigid base may comprise a recessed panel that is separated from the bottom by a standoff.

In some embodiments, the rigid base element may include a reclosable lid that selectively covers a spout opening through which the contents of the container may be accessed. The reclosable lid may be integral with the rigid base or it may be a separate component that is attached to the rigid base. The reclosable lid may be joined to the rigid base by a hinge, such as a living hinge. Thus, the lid may be selectively positioned in an open position and a closed position. In some embodiments, the spout opening has an external rib and the reclosable lid has an internal rib that engages the external rib when the reclosable lid is positioned in the closed position.

In some embodiments, the rigid base element further includes a locking tab for locking the reclosable lid in a closed position. In certain embodiments, the locking tab is moveable between a unlocked position and a locked position in which the reclosable lid is secured in the closed position.

Advantageously, in some embodiments, the rigid base and its associated components may be formed of a single, integral, and contiguous material. For example, the reclosable lid may be integral with the base, such as, by the use of a living hinge, and the locking feature, if present, may be similarly integrally formed with and a part of the rigid base. Such a feature may allow for the rigid base and its components to be manufactured economically and efficiently.

The rigid base may be formed in various shapes and sizes, including any polygonal, curvilinear or hybrid polygonal-curvilinear shape, including, but not limited to, triangular, quadrilateral, rectangular, square, trapezoidal, rhomboidal, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, decagonal, circular, oval, elliptical, Reuleaux polygonal, or combination of any number of the foregoing. Moreover, the shape may comprise one or more other features such as a fillet or a chamfer. In certain embodiments, the perimeter wall has at least one flat, substantially planar portion. The flat, substantially planar portion may be sufficiently large in area to allow the container to rest stably on a side without tipping over.

Methods of Manufacturing a Sturdy Base Container

In another aspect, a method of manufacturing a flexible sturdy base container is provided. The method may include transporting a rigid base element made of a relatively rigid material to a flexible wall element application station. The rigid base element may include a bottom and a perimeter wall having an outward facing surface. The method may further include applying a flexible wall element around the perimeter wall of the rigid base element at the flexible wall element application station without covering the bottom of the rigid base element. The flexible wall element may be made of a relatively flexible material. The method may further include affixing the flexible wall element to the perimeter wall of the rigid base element to produce the flexible sturdy base container. The method may further include forming an overlap of the flexible wall element in which the flexible wall element overlaps itself to form a lap seam. The method may further include affixing an outward-facing surface of the flexible wall element to an inward-facing surface of the flexible wall element at the lap seam.

In some embodiments, the method further includes transporting the flexible sturdy base container to a filling station, and filling the flexible sturdy base container with a bulk product while the flexible sturdy base container is at the filling station. In some embodiments, after being filled, the container may then be transported to a sealing station where an open end of the flexible wall element is sealed. For example, the open end may be sealed by heat sealing the flexible wall element to form a heat seal region. In certain embodiments, the step of sealing the open end of the flexible wall element comprises bonding opposite sides of the flexible wall element to form a bonding region. In certain embodiments, the open end of the flexible wall element may be sealed by compressing opposing reclosable elements together.

Various methods may be employed to apply the flexible wall element to the rigid base element. For example, in some embodiments, an open end of a tube of a relatively flexible material may be placed around the perimeter wall of the rigid base element. In other embodiments, the flexible wall element may be applied to the rigid base element by wrapping a sheet of a relatively flexible material around the perimeter wall of the rigid base element. The flexible wall element may be affixed to the perimeter wall by applying heat and/or pressure to the flexible wall element. The flexible wall element may be affixed to the rigid base element by various methods of affixing, including heat sealing, RF bonding, ultrasonic bonding, or adhesive bonding. For example, the flexible wall element may be bound to the perimeter wall by applying heat, pressure, ultrasonic energy, RF energy, or a combination thereof to the flexible wall element.

An embodiment of a system 200 and method for affixing a flexible wall element to a rigid base element is illustrated in FIG. 15. The rigid base 202 may be transported via a conveyor 204 to a tube application position 205. In embodiments of the flexible sturdy base container that include a recessed panel and standoff, the conveyor 204 may include gripping elements that insert into the space between the recessed panel and standoff to maintain positive control of the rigid base 202 as it is transported on the conveyor 202.

At the tube application position 205, an open end 208 of a tube 206 of flexible material is placed over the rigid base 202 and slid down the perimeter wall of the rigid base 202. The tube 206 may be formed as part of an inline process with the tube application process. For example, the tube 206 may be formed as part of a vertical form-fill-and-seal process on a production line. In other embodiments, the tube may be made prior to and independent of the application process. The tube 206 may include a series of reclosable elements 212 and/or easy open features 210, such as perforations or scores. The tube 206 may then be sealed to the rigid base 202, such as by applying heat and/or pressure. The top 214 of the flexible wall element may then be formed by cutting the tube 206 at the desired length.

Another embodiment of a system 300 and method for affixing a flexible wall element to a rigid bas element is illustrated in FIGS. 16A and 16B. The system 300 includes a rotating former 302, which includes a plurality of forming mandrels 316. At one position, a rigid base 320 is placed at one end of the mandrel 316, and the former 302 may then rotate so that the mandrel 316 is moved to a second position.

At the second position, a flexible wall element may be affixed to the rigid base by feeding a sheet of flexible packaging material 306 to the mandrel 316 while the mandrel 316 rotates about a longitudinal axis. While the flexible packaging material is wrapped around the mandrel 316, a heated roller 318 may apply heat and/or pressure to the flexible packaging material 306 so that the flexible packaging material bonds to the rigid base 320. In embodiments of the flexible sturdy base container that include a reclosable feature, a reclose material 308 may be fed from a reclose material roll 310 and joined to a flexible packaging material 306 fed from a flexible packaging roll 304 by a pressure roll 312 which applies heat and/or pressure to the reclose material 308 and/or flexible packaging material 306 as the two components pass across a guide roll 314. The reclose material 30 may be affixed to the flexible packaging material 306 by various methods of affixing, including heat sealing, RF bonding, ultrasonic bonding, or adhesive bonding. The flexible packaging material 306 may be cut to a length that will allow the flexible packaging material 306 to wrap completely around the mandrel 316 with an overlap.

The former 302 may then rotate to move the mandrel 316 to a third position. At the third position, a side sealing roll 324 may seal the flexible side wall element to itself from the top of the container to the bottom of the flexible side wall element. The container may then be discharged from the mandrel at the third position or at another position. In some embodiments, the container may discharged onto another conveyor that transports the container to a filling and/or sealing system.

An embodiment of a filling and sealing system 400 is illustrated in FIG. 17. The container 404 may be transported by a conveyor 408 to a fill position 406 where a fill tube 402 may be inserted through the open top of the container 404. The fill tube 402 may fill the container 404 with a product 410. The container 402 may then be transported by the conveyor 408 to a seal position 412. During the transport, the product 410 may be allowed to settle in the container 404. At the seal position, a heat seal 414 may be formed across the previously-open top of the container 404. The conveyor 408 may then transport the container 404 to another location for inspection and/or boxing or palletizing.

In some embodiments, a flexible sturdy base package forming system may be easily and quickly changed between forming and optionally, filling and sealing, containers of two or more different configurations. For example, the flexible sturdy base package forming system may first operate to form, fill, and seal a first container that is customized for a first product and then may be converted to operate to form, fill, and seal a second container that is customized for a second product with minimal equipment modification and downtime.

It will be appreciated that various of the above-disclosed and other feature and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 

1. A flexible sturdy base container comprising: a rigid base element comprising a relatively rigid material, the rigid base element comprising a bottom and a perimeter wall having an outward facing surface; and a flexible wall element comprising a relatively flexible material; wherein the flexible wall element is affixed to the outward facing surface of the perimeter wall of the rigid base element and extends in a direction away from the bottom of the rigid base element; and wherein the flexible wall element and the bottom of the rigid base element together form an exterior of the flexible sturdy base container.
 2. The flexible sturdy base container of claim 1, wherein the flexible wall element overlaps itself along a portion of the perimeter wall to form a lap seam.
 3. The flexible sturdy base container of claim 2, wherein an inward-facing surface of the flexible wall element is bonded to an outward-facing surface of the flexible wall element where the flexible wall element overlaps itself at the lap seam.
 4. The flexible sturdy base container of claim 1, the rigid base element further comprising a reclosable lid.
 5. The flexible sturdy base container of claim 4, further comprising a hinge connecting the reclosable lid to the rigid base element.
 6. The flexible sturdy base container of claim 5, wherein the hinge is a living hinge.
 7. The flexible sturdy base container of claim 4, the rigid base element further comprising a spout opening providing access to an interior of the container, the spout opening being selectively closable with the reclosable lid.
 8. The flexible sturdy base container of claim 7, the reclosable lid comprising an internal rib and the spout opening comprising an external rib, and wherein the internal rib engages the external rib when the reclosable lid is positioned in a closed position.
 9. The flexible sturdy base container of claim 1, wherein the flexible wall element covers only a first portion of the perimeter wall of the rigid base element thereby leaving a second portion of the perimeter wall exposed proximal the bottom of the rigid base element.
 10. The flexible sturdy base container of claim 1, wherein rigid base element comprises a molded or thermoformed article.
 11. The flexible sturdy base container of claim 1, wherein the relatively rigid material comprises a plastic material.
 12. The flexible sturdy base container of claim 1, wherein the rigid base element comprises a recessed panel and a standoff extending between the recessed panel and the bottom of the rigid base element.
 13. The flexible sturdy base container of claim 12, further comprising a reclosable lid attached to the recessed panel.
 14. The flexible sturdy base container of claim 1, wherein the perimeter wall has at least one flat, substantially planar portion.
 15. The flexible sturdy base container of claim 4, further comprising a locking tab for locking the reclosable lid in a closed position, the locking tab moveable between a unlocked position and a locked position.
 16. The flexible sturdy base container of claim 1, wherein the relatively flexible material comprises a polymeric material.
 17. The flexible sturdy base container of claim 1, wherein the relatively flexible material comprises a multilayer laminate structure.
 18. The flexible sturdy base container of claim 17, wherein the multilayer laminate structure comprises a heat-sealable inner layer comprising a heat sealable material.
 19. The flexible sturdy base container of claim 17, wherein the multilayer laminate structure comprises an oxygen and/or vapor barrier layer.
 20. The flexible sturdy base container of claim 17, wherein the multilayer laminate structure comprises a print layer.
 21. The flexible sturdy base container of claim 1, wherein the flexible wall element comprises a first end proximal to the bottom of the rigid base element and a second end distal to the bottom of the rigid base element, and wherein the second end of the flexible wall element comprises a heat seal region, the heat seal region hermetically sealing the container.
 22. The flexible sturdy base container of claim 21, wherein the flexible wall element further comprises a tear-away portion and a stress riser that facilitates the tearing away of the tear away portion.
 23. The flexible sturdy base container of claim 1, wherein the flexible wall element comprises a first end proximal to the bottom of the rigid base element and a second end distal to the bottom of the rigid base element, and wherein the second end of the flexible wall element comprises a reclosable element, the reclosable element allowing selective closure of the second end of the flexible wall element.
 24. The flexible sturdy base container of claim 1, wherein the container contains a bulk product. 